Organic light emitting display apparatus and method of manufacturing the same

ABSTRACT

Provided are an organic light emitting display apparatus and a method of manufacturing the same. The organic light emitting display apparatus includes: a thin film transistor (TFT) substrate including a plurality of thin film transistors, an organic light-emissive device on the TFT substrate, and an encapsulation layer on the TFT substrate and the organic light-emissive device, the encapsulation layer being configured to cover the organic light-emissive device, the encapsulation layer including a hybrid material including: a block copolymer, and functionalized graphene.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application is a continuation of U.S. patent application No.14/542,837, filed on Nov. 17, 2014, which claims benefit and priorityunder 35 U.S.C. §119(a) of Korean Patent Application No.10-2013-0144839, filed on Nov. 26, 2013, the entire disclosure of eachof which is hereby incorporated by reference herein for all purposes.

BACKGROUND

1. Technical Field

The following description relates to an organic light emitting displayapparatus and a method of manufacturing the same.

2. Discussion of the Related Art

As a type of flat panel display apparatus, liquid crystal display (LCD)apparatuses are being the most widely used at present. However, the LCDapparatuses are non-emissive devices that cannot self-emit light, andthus have problems in terms of brightness, a contrast ratio, and aviewing angle range.

As flat panel display apparatuses for overcoming the problems of the LCDapparatuses, organic light emitting display apparatuses are attractingmuch attention. The organic light emitting display apparatuses areemissive devices that self-emit light, and thus have relatively betterbrightness, contrast ratio, and viewing angle range than those of thenon-emissive devices. Also, because the organic light emitting displayapparatuses do not need a separate backlight, the organic light emittingdisplay apparatuses are implemented to have a lighter weight, a thinnerthickness, and lower power consumption compared to the LCD apparatuses.

An organic light emitting display apparatus fundamentally includes athin film transistor (TFT), a first electrode electrically connected tothe TFT, a light-emissive organic layer on the first electrode, and asecond electrode on the light-emissive organic layer. Because thelight-emissive organic layer is vulnerable to water and oxygen, astructure (hereinafter referred to as an “encapsulation structure”) forprotecting the light-emissive organic layer from external water oroxygen is needed for preventing a light-emissive defect which is causedby water or oxygen penetrating into the light-emissive organic layer.

FIGS. 1 to 3 are a cross-sectional views of related art organic lightemitting display apparatuses having different encapsulation structures(hereinafter referred to as first to third-type encapsulationstructures).

As illustrated in FIGS. 1 to 3, the organic light emitting displayapparatuses have the same configuration in that the organic lightemitting display apparatuses include a TFT substrate 10 including aplurality of TFTs (not shown) and an organic light-emissive device 20 onthe TFT substrate 10. A plurality of the organic light-emissive devices20 have the same configuration in that each of the organiclight-emissive devices 20 includes: a first electrode 21 that is formedon the TFT substrate 10 to be electrically connected to the TFT; a banklayer 22 that is formed on the TFT substrate 10 with the first electrode21 formed thereon, and includes a bank hole which exposes at least oneportion of the first electrode 21 corresponding to a light-emissivearea; a light-emissive organic layer 23 that is formed on a portion ofthe first electrode 21 exposed through the bank hole of the bank layer22; and a second electrode 24 that is formed on the light-emissiveorganic layer 23.

However, as illustrated in FIG. 1, the first-type encapsulationstructure includes: an encapsulation glass 31 that is separated from theorganic light-emissive device 20 by a certain distance; and a frit layer32 that is disposed between the TFT substrate 10 and the encapsulationglass 31 and at an edge of the organic light emitting display apparatus.

According to the first-type encapsulation structure, the encapsulationglass 31 mainly prevents oxygen/water from penetrating into thelight-emissive organic layer 23 through a face of the organic lightemitting display apparatus, and the frit layer 32 mainly preventsoxygen/water from penetrating into the light-emissive organic layer 23through a side of the organic light emitting display apparatus. However,the organic light emitting display apparatus having the first-typeencapsulation structure is vulnerable to an external impact, and it isimpossible to implement the organic light emitting display apparatus asa flexible display apparatus.

To overcome the drawbacks of the first-type encapsulation structure, thesecond-type and third-type encapsulation substructures have beenproposed.

According to the second-type encapsulation structure, as illustrated inFIG. 2, a protective layer 40 is formed on the TFT substrate 10 with theorganic light-emissive device 20 formed thereon to entirely cover theorganic light-emissive device 20, and an encapsulation plate 60 isadhered onto the TFT substrate 10 with the protective layer 40 formedthereon through an adhesive layer 50. The protective layer 40 includes:a first inorganic layer 41 that entirely covers the organiclight-emissive device 20; an organic layer 42 on the first inorganiclayer 41; and a second inorganic layer 43 on the organic layer 42.

According to the second-type encapsulation structure, the encapsulationplate 60 and the protective layer 40 mainly prevent oxygen/water frompenetrating into the light-emissive organic layer 23 through a face ofthe organic light emitting display apparatus, and the protective layer40 (in particular, the first inorganic layer 41) mainly preventsoxygen/water from penetrating into the light-emissive organic layer 23through a side of the organic light emitting display apparatus.

According to the third-type encapsulation structure, as illustrated inFIG. 3, a plurality of inorganic thin films 71 to 76 and a plurality oforganic thin films 81 to 85 are alternately formed on the TFT substrate10 with the organic light-emissive device 20 to entirely cover theorganic light-emissive device 20. According to the third-typeencapsulation structure, the inorganic thin films 71 to 76 and theorganic thin films 81 to 85 mainly prevent oxygen/water from penetratinginto the light-emissive organic layer 23 through a face of the organiclight emitting display apparatus. On the other hand, the inorganic thinfilm 71 mainly prevents oxygen/water from penetrating into thelight-emissive organic layer 23 through a side of the organic lightemitting display apparatus.

The above-described second-type encapsulation structure enables athickness of the organic light emitting display apparatus to be greatlyreduced, and enables a flexible display apparatus to be realized.However, because the encapsulation plate 60 cannot substantiallycontribute to preventing oxygen/water from penetrating in a directionparallel to the TFT substrate 10, the light-emissive organic layer 23 isexposed to oxygen/water, and for this reason, there is a relatively highpossibility that a quality of the organic light emitting displayapparatus is degraded. Also, it is required to use chemical vapordeposition (CVD)/atomic layer deposition (ALD) equipment and coatingequipment for forming the first and second inorganic layers 41 and 43and the organic layer 42, causing an increase in manufacturing cost.

The above-described third-type encapsulation structure uses aflexibility of the organic thin film and a cutoff of water by theinorganic thin film. In order to realize all merits of the organic thinfilms and the inorganic thin films, the organic thin films and theinorganic thin films are alternately formed. This makes themanufacturing process complicated, extends manufacturing time, and moreseverely increases cost. Also, because oxygen and water can easilypenetrate along an interface of each of the thin films (similarly to thesecond-type encapsulation structure) the third-type encapsulationstructure is also vulnerable to penetration of oxygen/water in thedirection parallel to the TFT substrate 10.

SUMMARY

Accordingly, embodiments of the present application are directed to anorganic light emitting display apparatus and a method of manufacturingthe same that substantially obviate one or more problems due tolimitations and disadvantages of the related art.

An object of embodiments is to provide an organic light emitting displayapparatus which has an excellent cutoff of water/oxygen and goodflexibility, and is manufactured through a relatively simple process atrelatively low cost.

Another object of embodiments is to provide a method of manufacturing anorganic light emitting display apparatus, having an excellent cutoff ofwater/oxygen and good flexibility, through a relatively simple processat relatively low cost.

Additional advantages, objects, and features of the disclosure will beset forth in part in the description which follows and in part willbecome apparent to those having ordinary skill in the art uponexamination of the following or may be learned from practice of theinvention. The objectives and other advantages of the invention may berealized and attained by the structure particularly pointed out in thewritten description and claims hereof as well as the appended drawings.

To achieve these objects and other advantages and in accordance with thepurpose according to one aspect of the invention, an organic lightemitting display apparatus, includes: a thin film transistor (TFT)substrate including a plurality of thin film transistors, an organiclight-emissive device on the TFT substrate, and an encapsulation layeron the TFT substrate and the organic light-emissive device, theencapsulation layer being configured to cover the organic light-emissivedevice, the encapsulation layer including a hybrid material including: ablock copolymer, and functionalized graphene.

In another aspect, a method of manufacturing an organic light emittingdisplay apparatus includes: preparing a substrate including a pluralityof thin film transistors, providing an organic light-emissive device onthe substrate, providing a protective layer on the substrate and theorganic light-emissive device to cover the organic light-emissivedevice, and forming an encapsulation layer on the substrate and theprotective layer to cover the protective layer, the forming of theencapsulation layer including: mixing functionalized graphene and ablock copolymer in a common solvent, for producing a mixed solution, andcoating the mixed solution on the substrate and the protective layer.

Other systems, methods, features and advantages will be, or will become,apparent to one with skill in the art upon examination of the followingfigures and detailed description. It is intended that all suchadditional systems, methods, features and advantages be included withinthis description, be within the scope of the present disclosure, and beprotected by the following claims. Nothing in this section should betaken as a limitation on those claims. Further aspects and advantagesare discussed below in conjunction with the embodiments. It is to beunderstood that both the foregoing general description and the followingdetailed description of the present disclosure are examples andexplanatory and are intended to provide further explanation of thedisclosure as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this specification, illustrate implementations of the inventionand together with the description serve to explain the principles of theinvention.

FIG. 1 is a cross-sectional view of a related art organic light emittingdisplay apparatus having a first-type encapsulation structure.

FIG. 2 is a cross-sectional view of a related art organic light emittingdisplay apparatus having a second-type encapsulation structure.

FIG. 3 is a cross-sectional view of a related art organic light emittingdisplay apparatus having a third-type encapsulation structure.

FIG. 4 is a cross-sectional view of an organic light emitting displayapparatus according to an embodiment.

FIG. 5 is a cross-sectional view of a TFT substrate according to anembodiment.

FIG. 6 is a cross-sectional view of a TFT substrate according to anembodiment.

FIGS. 7 to 9 and 11 to 13 are cross-sectional views for describing amethod of manufacturing an organic light emitting display apparatusaccording to an embodiment.

FIG. 10 is a chemical structural formula of functionalized grapheneaccording to an embodiment.

Throughout the drawings and the detailed description, unless otherwisedescribed, the same drawing reference numerals should be understood torefer to the same elements, features, and structures. The relative sizeand depiction of these elements may be exaggerated for clarity,illustration, and convenience.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the presentinvention, examples of which are illustrated in the accompanyingdrawings. In the following description, when a detailed description ofwell-known functions or configurations related to this document isdetermined to unnecessarily cloud a gist of the invention, the detaileddescription thereof will be omitted. The progression of processing stepsand/or operations described is an example; however, the sequence ofsteps and/or operations is not limited to that set forth herein and maybe changed as is known in the art, with the exception of steps and/oroperations necessarily occurring in a certain order. Like referencenumerals designate like elements throughout. Names of the respectiveelements used in the following explanations are selected only forconvenience of writing the specification and may be thus different fromthose used in actual products.

In the description of embodiments, when a structure is described asbeing positioned “on or above” or “under or below” another structure,this description should be construed as including a case in which thestructures contact each other as well as a case in which a thirdstructure is disposed therebetween.

The term “functionalized graphene” used herein denotes graphene having ahydrophilic group.

Hereinafter, embodiments will be described in detail with reference tothe accompanying drawings.

FIG. 4 is a cross-sectional view of an organic light emitting displayapparatus according to an embodiment. FIG. 5 is a cross-sectional viewof a TFT substrate according to an embodiment.

The organic light emitting display apparatus according to an embodimentmay include a TFT substrate 100 including a plurality of TFTs, anorganic light-emissive device 200 on the TFT substrate 100, and anencapsulation layer 400 formed on the TFT substrate 100 and the organiclight-emissive device 200 to cover the organic light-emissive device200.

According to an embodiment, as illustrated in the FIG. 4 example, theorganic light emitting display apparatus may further include aprotective layer 300 between the organic light-emissive device (OLED)200 and the encapsulation layer 400, a polarizer 500 on theencapsulation layer 400, and a front module 700 adhered to the polarizer500 by an adhesive layer 600 disposed between the front module 700 andthe polarizer 500.

As illustrated in the FIG. 5 example, the TFT substrate 100 according toan embodiment may include a polyimide film 110, a buffer layer 120 onone surface of the polyimide film 110, a TFT 130 and a capacitor 140disposed on the buffer layer 120, and a rear plate 190 adhered to theother surface of the polyimide film 110 by an adhesive layer 180disposed between the rear plate 190 and the other surface of thepolyimide film 110.

The TFT 130 may include a semiconductor layer 131, a gate electrode 132,a source electrode 133, and a drain electrode 134. The capacitor 140 mayinclude a lower electrode 141 and a capacitor upper electrode 142.

A gate insulating layer 150 may be disposed between the semiconductorlayer 131 and the gate electrode 132, and between the capacitor lowerelectrode 141 and the capacitor upper electrode 142. An inter-layerdielectric 160 may be disposed on the capacitor upper electrode 141, andbetween the gate electrode 131 and the source and drain electrodes 133,134. An overcoat layer 170 may be disposed on the inter-layer dielectric160 and the source and drain electrodes 133, 134 for protecting the TFT130 and the capacitor 140, and for planarizing a step height caused bythe TFT 130. A first electrode 210 of the organic light-emissive device200 may be electrically connected to the drain electrode 134 of the TFT130 through a hole formed in the overcoat layer 170.

The TFT substrate 100 of the FIG. 5 example may have a structure forimplementing a flexible display apparatus, and may include a top-gateTFT in which the gate electrode 132 is disposed on the semiconductorlayer 131, but embodiments are not limited thereto. For example, the TFTsubstrate 100 may include a bottom-gate TFT in which the gate electrode132 is disposed under the semiconductor layer 131, and may have anon-flexible structure.

For example, as illustrated in the FIG. 6 example, a TFT substrate 100′may include a substrate 111 formed, e.g., of a glass or plasticmaterial, a gate electrode 113 a on the substrate 111, a gate insulatinglayer 112 on the substrate 111 and the gate electrode 113 a, asemiconductor layer 113 b that may overlap the gate electrode 113 a withthe gate insulating layer 112 therebetween, a source electrode 113 c anda drain electrode 113 d (formed on the gate insulating layer 112 and thesemiconductor layer 113 b to be separated from each other), and aninorganic insulating layer 114 and an organic insulating layer 115 thatare sequentially formed on the substrate 111 with the TFT 113 formedthereon. The first electrode 210 of the organic light-emissive device200 may be electrically connected to the drain electrode 113 d of theTFT 113 through a hole which may be formed in the inorganic insulatinglayer 114 and the organic insulating layer 115.

Hereinafter, the organic light-emissive device 200 on the TFT substrate100 will be described in more detail with reference to the FIG. 4example.

The organic light-emissive device 200 according to an embodiment mayinclude a first electrode 210 on the TFT substrate 100, a bank layer 220on the TFT substrate 100 with the first electrode 210 disposed thereon,a light-emissive organic layer 230 on a portion of the first electrode210 exposed through the bank hole of the bank layer 220, a secondelectrode 240 on the light-emissive organic layer 230, and a cappinglayer 250 on the second electrode 240. The bank layer 220 may include abank hole which exposes at least one portion of the first electrode 210corresponding to a light-emissive area.

The first electrode 210 may be electrically connected to the TFT 130(e.g., to the drain electrode 134) of the TFT substrate 100. The firstelectrode 210 may be an anode electrode, and may be formed of atransparent conductive material, which may have a high work function,such as indium tin oxide (ITO), indium zinc oxide (IZO), indium tin zincoxide (ITZO), indium cerium oxide (ICO), or ZnO.

The bank hole of the bank layer 220 may define a light-emissive area byexposing at least one portion of the first electrode 210. Thelight-emissive organic layer 230 (which may be disposed on a portion ofeach of the first electrode 210 and bank layer 220 exposed through thebank hole of the bank layer 220) may include a light-emissive layer, ahole injection layer and/or a hole transport layer between the firstelectrode 210 and the light-emissive layer, and an electron injectionlayer and/or an electron transport layer between the second electrode240 and the light-emissive layer.

The second electrode 240 disposed on the light-emissive organic layer230 may be a cathode electrode, and may be formed of aluminum (Al),magnesium (Mg), calcium (Ca), silver (Ag), or an alloy thereof, whichmay have a low work function.

The organic light emitting display apparatus according to an embodimentmay be a bottom-emission type, in which light emitted from thelight-emissive organic layer 230 passes through the TFT substrate 100,or a top-emission type in which the light emitted from thelight-emissive organic layer 230 passes through the front module 700. Inthe bottom-emission type, the second electrode 240 may have a sufficientthickness that enables light to be reflected.

On the other hand, in the top-emission type, the second electrode 240may have a thin thickness (for example, 1 to 50 Å) that enables light tobe transmitted. A reflective layer (not shown) formed of Al, Ag, ornickel (Ni) may be disposed under the first electrode 210. Also, asillustrated in the FIG. 4 example, the capping layer 250 may be formedon the second electrode 240. The capping layer 250 may prevent light,emitted from the light-emissive organic layer 230, from being totallyreflected from a top of the second electrode 240, and may be formed of amixture of a conductive inorganic material and an organic material. Theconductive inorganic material may use, for example, a transition metal,an alkali metal, an alkali earth metal, a rare-earth metal, and/or analloy of two or more thereof. The organic material may use an organicmaterial (for example, a material which is usable as a host material ofthe hole transport layer) having good hole mobility or an organicmaterial (for example, a material which is usable as a host material ofthe electron transport layer) having good electron mobility. Theconductive inorganic material may causes a surface plasmon resonance inthe capping layer 250 to increase scattering and absorption of light andto prevent the light from being totally reflected from the top of thesecond electrode 240, thereby enhancing a light extraction effect of theorganic light emitting display apparatus.

The organic light emitting display apparatus according to an embodiment,as illustrated in the FIG. 4 example, may include the encapsulationlayer 400 on the TFT substrate 100 and the organic light-emissive device200 to cover the organic light-emissive device 200. The encapsulationlayer 400 may prevent water or oxygen from penetrating into thelight-emissive organic layer 230, and thus may entirely cover theorganic light-emissive device 200.

The encapsulation layer 400 may include a hybrid material formed from ablock copolymer and functionalized graphene. As described above, thefunctionalized graphene denotes graphene having a hydrophilic group.

Graphene has a two-dimensional (2D) honeycomb structure composed of sp²carbon atoms. Graphene has a very stable structure in which a singlebond and a double bond are conjugated, and has good mechanical strength,flexibility, and light transmittance. Therefore, graphene is a materialsuitable for an encapsulation structure of the organic light emittingdisplay apparatus. Above all, a carbon chain size of graphene is lessthan a diameter of a water molecule, and thus, graphene has veryexcellent water/oxygen cutoff characteristic.

The block copolymer has a self-assembly characteristic for minimizingthermodynamic energy. A uniform micro-phase separation of blocks iscaused by the self-assembly, and micro-domains having a size of severalnanometers (nm) to tens of nm may be formed. Various types ofmicro-structures including a lamellar structure suitable for theencapsulation structure of the organic light emitting display apparatusmay be formed through the self-assembly of the block copolymer. The typeof the micro-structure of the block copolymer formed through theself-assembly may be controlled by adjusting a volume fraction of ahomopolymer forming each block. That is, the block copolymer beingself-assembled to a certain type of micro-structure may be induced byadjusting a volume fraction of homopolymers.

Embodiments may have a feature in that the encapsulation layer 400 isformed of a hybrid material that is formed by chemical bonding of thefunctionalized graphene and the block copolymer, and thus, a very goodbarrier characteristic of graphene is applied to self-assembly inductiontechnology of the block copolymer.

The encapsulation layer 400 having a multi-layer structure (e.g., thelamellar structure) may be formed by inducing the self-assembly of theblock copolymer to the lamellar structure, which is suitable for theencapsulation structure of the organic light emitting display apparatus,and chemically bonding the functionalized graphene to the homopolymersforming odd layers or even layers of the lamellar structure.

Hereinafter, the lamellar structure of the encapsulation layer 400according to an embodiment will be described in more detail withreference to the FIG. 4 example.

The block copolymer according to an embodiment, which is chemicallybonded to the functionalized graphene, may include at least onehydrophilic homopolymer and at least one hydrophobic homopolymer. Forexample, the block copolymer may be a block copolymer (PS-b-PEO) ofpolystyrene and polyethylene oxide, a block copolymer (PS-b-PDMS) ofpolystyrene and polydimethylsiloxane, a block copolymer (PI-b-PEO) ofpolyimide and polyethylene oxide, or a mixture of two or more thereof.The hydrophilic group of the functionalized graphene may be chemicallybonded to the hydrophilic homopolymer of the block copolymer.

The encapsulation layer 400 may include a first layer 410, which may beformed by chemical bonding of the functionalized graphene and thehydrophilic homopolymer (for example, PEO or PDMS), and a second layer420 including the hydrophobic homopolymer (for example, PS or PI).According to an embodiment, the encapsulation layer 400 may have alamellar structure in which the first and second layers 410 and 420 arealternately stacked at least twice or more.

The encapsulation layer 400 according to an embodiment formed by coatingor printing a liquid material has a good step coverage characteristic,and thus, all the first and second layers 410 and 420 configuring theencapsulation layer 400 can prevent oxygen/water from penetratingthrough a side of the organic light emitting display apparatus as wellas from penetrating through a face thereof. Because the good stepcoverage characteristic of the encapsulation layer 400 is added to thegood barrier characteristic of graphene itself, the organic lightemitting display apparatus according to en embodiment has a moreenhanced water/oxygen cutoff characteristic than that of the relatedart. Moreover, the encapsulation layer 400 according to an embodimentincludes graphene having a good bending characteristic, thereby givingbetter flexibility to the organic light emitting display apparatus.

As illustrated in the example of FIG. 4, the organic light emittingdisplay apparatus according to an embodiment may further include theprotective layer 300 between the organic light-emissive device 200 andthe encapsulation layer 400. The protective layer 300 may be formed of amaterial containing, e.g., one or more of Al₂O₃, SiO₂, Si₃N₄, SiON,AlON, AlN, TiO₂, ZrO, ZnO, and Ta₂O₅.

The protective layer 300 is a layer for minimizing an influence of thesolvent (a common solvent of the functionalized graphene and the blockcopolymer, for example, propylene glycol monomethyl ether acetate(PGMEA), toluene, or the like), which may be used to form theencapsulation layer 400, on the light-emissive organic layer 230 of theorganic light-emissive device 200. To this end, according to anembodiment, the protective layer 300 may be formed on the TFT substrate100 and the organic light-emissive device 200 to entirely cover theorganic light-emissive device 200, thereby preventing a direct contactof the organic light-emissive device 200 and the encapsulation layer400.

As illustrated in the FIG. 4 example, the organic light emitting displayapparatus according to an embodiment may further include the polarizer500 on the encapsulation layer 400, the front module 700, and theadhesive layer 600 therebetween. The polarizer 500 may be provided forpreventing a reduction in visibility which may be caused by externallight (reflected by the organic light-emissive device 200) being emittedfrom the organic light emitting display apparatus, and may prevent theexternal light, reflected by the second electrode 240 of the organiclight-emissive device 200, from being emitted from the organic lightemitting display apparatus.

The polarizer 500 may include a λ/4 phase difference film on theencapsulation layer 400 and a linear polarization film on the λ/4 phasedifference film. The external light is changed to linearly-polarizedlight by passing through the linear polarization film. Thelinearly-polarized light may pass through the λ/4 phase difference film,may be reflected by the second electrode 240, may again pass through theλ/4 phase difference film to thereby be changed to linearly-polarizedlight vertical to a transmissive axis of the linear polarization film,and may be absorbed by the linear polarization film.

The front module 700 may include a touch film 710 and a cover window720, and may be adhered to the polarizer 500 through the adhesive layer600. The cover window 710 may be formed of glass or plastic. A pressuresensitive adhesive (PSA), an optically clear adhesive (OCA), or the likemay be used for the adhesive layer 600.

Hereinafter, a method of manufacturing the organic light emittingdisplay apparatus according to an embodiment will be described in detailwith reference to FIGS. 7 to 13.

First, as illustrated in the FIG. 7 example, a substrate 100 a includinga TFT 130 may be prepared, and then, an organic light-emissive device200 may be formed on the substrate 100 a. In order to prepare thesubstrate 100 a, a polyimide film 110 may be formed on a glass substrate101. Subsequently, a buffer layer 120 may be formed of an inorganicmaterial on the polyimide film 110.

A semiconductor layer 131 and a capacitor lower electrode 141 may beformed on the buffer layer 120 to be separated from each other. Thesemiconductor layer 131 may be, e.g., amorphous silicon, polycrystallinesilicon, or oxide semiconductor.

A gate insulating layer 150 may be formed on the buffer layer 120 onwhich the semiconductor layer 131 and capacitor lower electrode 141 maybe formed. The gate insulating layer 150 may be formed, e.g., of siliconoxide (SiO_(x)) or silicon nitride (SiN_(x)).

A gate electrode 132 and a capacitor upper electrode 142 may be formedon the gate insulating layer 150 to respectively overlap thesemiconductor layer 131 and the capacitor lower electrode 141. The gateelectrode 132 and the capacitor upper electrode 142 may be formed, e.g.,of Al, Mo, Cr, Au, Ti, Ni, Cu, or an alloy of two or more thereof.

Subsequently, an inter-layer dielectric 160 may be formed on the gateinsulating layer 150 on which the gate electrode 132 and the capacitorupper electrode 142 may be formed. The inter-layer dielectric 160 maybe, e.g., an organic single layer or an inorganic/organic double layer.

Two via holes partially exposing the semiconductor layer 131 may beformed by selectively etching the inter-layer dielectric 160 and thegate insulating layer 150 at both sides of the gate electrode 132 withthe gate electrode 132 therebetween. Subsequently, a metal layer may beformed, for example, of Al, Mo, Cr, Au, Ti, Ni, Cu, or an alloy of twoor more thereof on the inter-layer dielectric 160. Then, a sourceelectrode 133 and a drain electrode 134 may be formed by performing aphotolithography process and an etching process.

An overcoat layer 170 may be disposed on the inter-layer dielectric 160on which the source and drain electrodes 133 and 134 are formed, forprotecting the TFT 130 and the capacitor 140 and for planarizing a stepheight caused by the TFT 130. The overcoat layer 170 may be, e.g., anorganic single layer or an inorganic/organic double layer.

In order to form the organic light-emissive device 200 on the finishedsubstrate 100 a, a hole partially exposing the drain electrode 134 maybe formed by selectively etching the overcoat layer 170. Subsequently, atransparent conductive material, which may have a high work function,such as ITO, IZO, ITZO, ICO, or ZnO, may be deposited through a CVD orsputtering process. Then, a first electrode 210 may be formed byperforming a photolithography process and an etching process. Inmanufacturing a top-emission type organic light emitting displayapparatus, immediately before forming the first electrode 210, areflective layer (not shown) may be formed of Ag or Ni on the substrate100 a.

An organic insulating layer may be formed of an organic non-conductivematerial, such as benzocyclobutene (BCB), an acrylic resin, an epoxyresin, a polyamide resin, or a polyimide resin, on the substrate 100 awith the first electrode 210 formed thereon. Then, a bank layer 220partially exposing at least one portion of the first electrode 210 maybe formed by performing a selective etching process.

Subsequently, through a general method, a light-emissive organic layer230, a second electrode 240, and a capping layer 250 may be sequentiallyformed on the bank layer 220 and the first electrode 210. The secondelectrode 240 disposed on the light-emissive organic layer 230 may beformed, e.g., of aluminum (Al), magnesium (Mg), calcium (Ca), silver(Ag), or an alloy thereof, which may have a low work function. Inmanufacturing a bottom-emission type organic light emitting displayapparatus, the second electrode 240 may have a sufficient thickness thatenables light to be reflected. On the other hand, in manufacturing thetop-emission type organic light emitting display apparatus, the secondelectrode 240 may have a thin thickness (for example, 1 to 50 Å) thatenables light to be transmitted.

A capping layer 250 for preventing light, emitted from thelight-emissive organic layer 230, to be totally reflected from a top ofthe second electrode 240 may be formed on the second electrode 240. Thecapping layer 250 may have a thickness of about 10 nanometers (nm) orabout 100 nm.

As described above, the capping layer 250 may be formed of a mixture ofa conductive inorganic material and an organic material. The conductiveinorganic material may use, for example, a transition metal, a alkalimetal, an alkali earth metal, a rare-earth metal, and/or an alloy of twoor more thereof. For example, when a silver nanoparticle is used as theconductive inorganic material, silver nanoparticles and organicmaterials may be sprayed and deposited on the second electrode 240,thereby forming the capping layer 250. A content of silver nanoparticlesincluded in the capping layer 250 may be 10 percent by weight (wt %) orless.

Subsequently, as illustrated in the FIG. 8 example, a protective layer300 may be formed on the TFT substrate 10 and the organic light-emissivedevice 20 to entirely cover the organic light-emissive device 20. Theprotective layer 300 may be formed, e.g., of a material containing oneor more of Al₂O₃, SiO₂, Si₃N₄, SiON, AlON, AlN, TiO₂, ZrO, ZnO, andTa₂O₅. Because there is a risk of damaging the light-emissive organiclayer 230 under a high temperature of 100° (degrees) C. or more, theprotective layer 300 may be formed by performing a plasma-enhancedchemical vapor deposition (PECVD) or ALD process under a low temperatureof 80° C. to 100° C.

Subsequently, as illustrated in the FIG. 9 example, an encapsulationlayer 400 may be formed on the substrate 100 a and on the protectivelayer 300 to cover the protective layer 300. According to an embodiment,an operation of forming the encapsulation layer may include an operationof mixing the functionalized graphene and the block copolymer in acommon solvent for producing a mixed solution and an operation ofcoating the mixed solution on the substrate 100 a and the protectivelayer 400.

The functionalized graphene may be produced by using various knownmethods (for example, a Hummers method that is one of representativemethods of producing graphene oxide (GO)) of producing GO.

According to an embodiment, the functionalized graphene may be producedas follows:

1) Expanded graphite is put into a sulfate solution, and slurry isproduced;

2) Potassium permanganate is gradually added while stirring the slurry,and simultaneously, a cooling process is performed to maintain atemperature of the solution at 20° (degrees) C. or less, for preventingexplosion caused by the addition of the potassium permanganate;

3) The slurry is stirred for about two hours under about 35° (degrees)C., and distilled water is added;

4) To remove metal ions from the slurry, the slurry is washed with 1:10hydrochloric acid, and filtered;

5) To neutralize a paste obtained in this way, a process in which thepaste is put into distilled water, stirred, and filtered is repeatedtwice or three times; and

6) Remaining graphite oxide (e.g., unexfoliated graphite oxide) isremoved by centrifuging a neutralized oxide graphene solution at about4,000 RPM (revolutions per minute) or more.

As described above, the Hummers method uses potassium permanganate andsulfate. The potassium permanganate is an oxidant which is generallyused, but an active species that actually oxidizes expanded graphite isdimanganese heptoxide. The dimanganese heptoxide is produced by anaction between potassium permanganate and sulfate as follows:KMnO₄+3H₂SO₄→K⁺+MnO₃ ⁺+H₃O⁺+3HSO₄ ⁻MnO₃ ⁺+MnO₄ ⁻→Mn₂O₇

FIG. 10 is a chemical structural formula of functionalized grapheneaccording to an embodiment. As illustrated in FIG. 10, thefunctionalized graphene according to the present invention may includean epoxy group (A), a hydroxyl group (B), and/or a carboxyl group (C) asa hydrophilic group.

The block copolymer according to an embodiment may include at least onehydrophilic homopolymer and at least one hydrophobic homopolymer. Forexample, the block copolymer may be a block copolymer (PS-b-PEO) ofpolystyrene and polyethylene oxide, a block copolymer (PS-b-PDMS) ofpolystyrene and polydimethylsiloxane, a block copolymer (PI-b-PEO) ofpolyimide and polyethylene oxide, or a mixture of two or more thereof.

The type of the micro-structure of the block copolymer formed throughthe self-assembly may be controlled by adjusting a volume fraction of ahomopolymer forming each block. Therefore, according to an embodiment,the block copolymer being self-assembled to the lamellar structuresuitable for the encapsulation structure of the organic light emittingdisplay apparatus may be induced by adjusting a volume fraction of thehomopolymers.

According to an embodiment, a volume fraction of the hydrophilichomopolymer in the block copolymer may be 0.3 to 0.7. In particular,when the block copolymer is the block copolymer (PS-b-PEO) ofpolystyrene and polyethylene oxide or the block copolymer (PI-b-PEO) ofpolyimide and polyethylene oxide, the volume fraction of the hydrophilichomopolymer (i.e., polyethylene oxide (PEO)) in the block copolymer maybe 0.4 to 0.5.

As described above, the block copolymer (of which the volume fraction ofthe hydrophilic homopolymer is adjusted to be self-assembled in thelamellar structure) and the functionalized graphene having thehydrophilic group may be mixed in a common solvent, thereby producing amixed solution. The common solvent may be a solvent having miscibilitywith the functionalized graphene and the block copolymer, and forexample, may include PGMEA, toluene, or the like.

The mixed solution may be coated on the substrate 100 a and theprotective layer 400. Then, the encapsulation layer 400 may be formed byperforming an annealing process. The coating of the mixed solution maybe performed, for example, by a spin coating process, a slot die coatingprocess, a slit coating process, a drop casting process, or an inkjetprinting process.

The annealing process may be performed for 0.5 hours to 1 hour under anormal temperature to about 80° (degrees) C. by using a saturatedorganic solvent vapor (for example, saturated acetone or toluene) suchas acetone or toluene.

According to the above-described method, the encapsulation layer 400 mayhave the lamellar structure in which the first layer 410, which may beformed by the chemical bonding of the functionalized graphene and thehydrophilic homopolymer (for example, PEO or PDMS), and the second layer420 including the hydrophobic homopolymer (for example, PS or PI) may bealternately stacked at least twice or more.

The encapsulation layer 400 according to an embodiment which is formedby a coating or printing process in a liquid state may have a good stepcoverage characteristic, thereby further enhancing the water/oxygencutoff characteristic of the organic light emitting display apparatus.

Moreover, according to embodiments, because the encapsulation layer 400having the multi-layer lamellar structure may be formed by performingonly a one-time coating process without performing a CVD process whichrequires expensive equipment and time to create a vacuum environment,the manufacturing process can be innovatively simplified, manufacturingtime can be considerably shortened, and manufacturing cost can beconsiderably reduced.

After the encapsulation layer 400, as illustrated in the FIG. 11example, the polarizer 500 may be adhered to the encapsulation layer400. Then, the front module 700 including the touch film 710 and thecover window 720 may be adhered to the polarizer 500 through theadhesive layer 600 such as a PSA or an OCA.

Subsequently, as illustrated in the FIG. 12 example, the glass substrate101 performing a support function in a manufacturing process may beseparated from the polyimide film 110, e.g., by using a laser. For sucha separation process, heating and dissolving may be performed byabsorbing an irradiated laser. Thus, a sacrificial layer (not shown)enabling the separation between the glass substrate 101 and thepolyimide film 110 may be further formed between the glass substrate 101and the polyimide film 110.

The glass substrate 101 may be separated from the polyimide film 110.Then, as illustrated in the FIG. 13 example, the rear plate 190 forsupporting the organic light emitting display apparatus may be adheredto the polyimide film 110 through the adhesive layer 180, which may be,for example, a PSA or an OCA.

According to embodiments, external water and oxygen may be completelycut off, and a reliability and service life of the organic lightemitting display apparatus may increase. Moreover, a flexibility of theorganic light emitting display apparatus may be enhanced. Thus, anext-generation flexible display apparatus and foldable displayapparatus bendable at a larger curvature radius may be implemented.

Moreover, the organic light emitting display apparatus with an excellentcutoff of water/oxygen and good flexibility may be manufactured with athinner thickness that the related art apparatus. Moreover, according toembodiments, the organic light emitting display apparatus with anexcellent cutoff of water/oxygen and good flexibility may bemanufactured through a relatively simple process at relatively low cost.

The block copolymer may include at least one hydrophilic homopolymer andat least one hydrophobic homopolymer, and the encapsulation layer mayinclude: a first layer formed by chemical bonding of the functionalizedgraphene and the hydrophilic homopolymer; and a second layer includingthe hydrophobic homopolymer. The encapsulation layer may have a lamellarstructure in which the first and second layers are alternately stackedat least twice or more. The block copolymer may be a block copolymer ofpolystyrene and polyethylene oxide, a block copolymer of polystyrene andpolydimethylsiloxane, a block copolymer of polyimide and polyethyleneoxide, or a mixture of two or more thereof.

The organic light emitting display apparatus according to an embodimentmay further include a protective layer between the organiclight-emissive device and the encapsulation layer. The protective layermay be formed on the TFT substrate and the organic light-emissive deviceto entirely cover the organic light-emissive device, and may prevent adirect contact of the organic light-emissive device and theencapsulation layer. The protective layer may be formed, e.g., of amaterial containing one or more of Al₂O₃, SiO₂, Si₃N₄, SiON, AlON, AlN,TiO₂, ZrO, ZnO, and Ta₂O₅.

The block copolymer may include at least one hydrophilic homopolymer andat least one hydrophobic homopolymer. A volume fraction of thehydrophilic homopolymer in the block copolymer may be 0.3 to 0.7. Theblock copolymer may be a block copolymer of polystyrene and polyethyleneoxide, a block copolymer of polystyrene and polydimethylsiloxane, ablock copolymer of polyimide and polyethylene oxide, or a mixture of twoor more thereof. The block copolymer may be a block copolymer ofpolystyrene and polyethylene oxide or a block copolymer of polyimide andpolyethylene oxide. A volume fraction of the hydrophilic homopolymer inthe block copolymer may be 0.4 to 0.5.

A method of manufacturing an apparatus according to an embodiment mayfurther include annealing the coated mixed solution. The annealing maybe performed by using a saturated organic solvent vapor. The coating ofthe mixed solution may be performed, for example, by a spin coatingprocess, a slot die coating process, a slit coating process, a dropcasting process, or an inkjet printing process.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the present inventionwithout departing from the spirit or scope of the invention. Thus, it isintended that embodiments of the present invention cover themodifications and variations of this invention provided they come withinthe scope of the appended claims and their equivalents.

What is claimed is:
 1. An organic light emitting display apparatus,comprising: an organic light-emissive device; and a lamellar structureconfigured to encapsulate the organic light-emissive device, wherein thelamellar structure includes: first and second two-dimensional honeycombstructures of carbon atoms, the first and second honeycomb structuresbeing spaced apart from each other; and a block copolymer between thefirst and second honeycomb structures.
 2. The organic light emittingdisplay apparatus of claim 1, wherein the block copolymer includes ahydrophilic homopolymer and a hydrophobic homopolymer.
 3. The organiclight emitting display apparatus of claim 2, wherein: at least one ofthe first and second honeycomb structures is functionalized with ahydrophilic group; and the hydrophilic group is chemically bonded to thehydrophilic homopolymer of the block copolymer.
 4. The organic lightemitting display apparatus of claim 2, wherein the block copolymer is ablock copolymer of polystyrene and polyethylene oxide, a block copolymerof polystyrene and polydimethylsiloxane, or a block copolymer ofpolyimide and polyethylene oxide.
 5. The organic light emitting displayapparatus of claim 1, wherein: the lamellar structure comprises first,second, and third layers sequentially stacked; the first and thirdlayers include the first and second honeycomb structures, respectively;and the second layer includes the block copolymer.
 6. A lamellarstructure, comprising: first and second two-dimensional honeycombstructures of carbon atoms, the first and second honeycomb structuresbeing spaced apart from each other in the lamellar structure; and ablock copolymer between the first and second honeycomb structures. 7.The lamellar structure of claim 6, wherein the block copolymer includesa hydrophilic homopolymer and a hydrophobic homopolymer.
 8. The lamellarstructure of claim 7, wherein: at least one of the first and secondhoneycomb structures is functionalized with a hydrophilic group; and thehydrophilic group is chemically bonded to the hydrophilic homopolymer ofthe block copolymer.
 9. The lamellar structure of claim 6, wherein theblock copolymer is a block copolymer of polystyrene and polyethyleneoxide, a block copolymer of polystyrene and polydimethylsiloxane, or ablock copolymer of polyimide and polyethylene oxide.
 10. The lamellarstructure of claim 6, wherein: the lamellar structure comprises first,second, and third layers sequentially stacked; the first and thirdlayers include the first and second honeycomb structures, respectively;and the second layer includes the block copolymer.
 11. A method formanufacturing a lamellar structure, the method comprising: mixing ablock copolymer and two-dimensional honeycomb structures of carbon atomsin a common solvent to produce a mixed solution, the block copolymerbeing capable of self-assembling into a lamellar structure; andannealing the mixed solution.
 12. The method of claim 11, wherein: thehoneycomb structures are functionalized with a hydrophilic group; theblock copolymer includes a hydrophilic homopolymer and a hydrophobichomopolymer; and a volume fraction of the hydrophilic homopolymer in theblock copolymer is 0.3 to 0.7.
 13. The method of claim 11, wherein theblock copolymer is a block copolymer of polystyrene and polyethyleneoxide, a block copolymer of polystyrene and polydimethylsiloxane, or ablock copolymer of polyimide and polyethylene oxide.
 14. The method ofclaim 13, wherein: the block copolymer is a block copolymer ofpolystyrene and polyethylene oxide or a block copolymer of polyimide andpolyethylene oxide; and a volume fraction of the polyethylene oxide inthe block copolymer is 0.4 to 0.5.